Smart Battery Capacity Testing Solution
What Is Smart Battery Capacity Testing?
Smart Battery Capacity Testing is an AI-driven, constant-current discharge technology that evaluates the actual capacity (Ah) and state of health (SOH) of a battery bank in real time.
Unlike traditional manual load-bank discharge methods, the DFUN system achieves:
Online testing without power interruption
Real-load discharge with intelligent protection
Automatic capacity calculation and report generation
Remote monitoring and historical trend tracking
This makes it ideal for data centers, substations, telecom sites, and utility control rooms, ensuring safe, automated, and unmanned battery maintenance.
Why Perform Regular Battery Capacity Testing?
Improve System Reliability
Batteries lose capacity over time due to long-term float charging. Regular testing ensures enough backup during power outages.
Prevent Safety Risks
Capacity testing helps identify weak or failed cells early, preventing unexpected UPS or DC power failures.
Optimize Maintenance and Costs
Accurate testing provides a data-driven basis for replacement, avoiding unnecessary full-bank changes.
Meet International Standards
Compliant with IEC, IEEE, and GB/T standards recommending capacity testing every 6–12 months for system reliability and auditability.
Limitations of Traditional Capacity Testing
Manual load-bank testing generates excessive heat and energy waste
Requires disconnecting the battery from the system, causing downtime risk
Manual data recording is error-prone and inconsistent
Single-bank tests can only reach 50% of rated capacity
DFUN’s intelligent testing system eliminates these issues through fully automated control, AI analysis, and cloud-based reporting.
DFUN Technological Breakthroughs
1. Online Testing with Zero Interruption
Innovative K/D structure with dual redundancy ensures the system remains live during testing.
2. True Load Discharge without Artificial Heat
Energy is fed back to the DC bus via DC/DC conversion, using the actual load—safe and efficient.
3. AI-Based Analysis & Capacity Prediction
Advanced AI models analyze voltage, current, and temperature curves to predict SOH with >95% accuracy.
4. Remote Operation and Cloud Reporting
Real-time web interface for monitoring, with automated PDF/Excel report generation and remote diagnosis.
5. Multi-Layer Safety Protection
18 built-in protection mechanisms: over-temperature, over-current, short-circuit, reverse polarity, and communication fault alarms.
Industry Application Scenarios
The DFUN Battery Monitoring System stands out in the market by addressing the core needs of efficient, safe, and adaptable battery management. Its competitive edges stem from a focus on precision, flexibility, and reliability—designed to outperform conventional solutions in critical scenarios.
Telecom Power Systems (48 V)
Online capacity testing with zero downtime
DC/DC energy feedback to system bus
Full-bank testing with 48 V lithium modules
Automated encrypted data reporting
Power Operation Systems (110 V / 220 V)
Flexible grid connection with true load discharge
Harmonic suppression and soft current rise
Online standby and shallow-cycle maintenance
IEC 61850 / 104 protocol compatibility
UPS & Data-Center Systems (380 V / 480 V)
Dual-bus architecture for zero-risk discharge
Independent multi-bank management
Auto isolation of charging circuits
Unified remote monitoring platform
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Core Functional Highlights
1️⃣ True Load Discharge: PCS-based discharge without rewiring.
2️⃣ Full Online Standby: Always ready via normally-closed diode design.
3️⃣ Smooth Constant-Current Charging: Prevents voltage spikes and cell stress.
4️⃣ Comprehensive Monitoring: Real-time voltage, current, and comms diagnostics.
5️⃣ Harmonic Suppression: Ensures grid power quality compliance.
6️⃣ Battery Maintenance & Open-Circuit Detection: Shallow charge/discharge for activation and early fault detection.
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System Advantages
Fully automated, unmanned testing
AI-driven capacity and lifetime analytics
18-layer protection architecture
Cloud-based reporting and data traceability
Compatible with lead-acid and lithium systems
Seamless integration with DFUN PBMS 9000 / 2000
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Technical Highlights
| Parameter | Specification |
| Voltage Range | 48 V / 110 V / 220 V / 380 V / 480 V |
| Discharge Current | 20 A – 240 A (customizable) |
| Capacity Range | ≤ 2000 Ah |
| Measurement Accuracy | ± 1 % FS |
| Operating Temperature | –10 °C ~ +50 °C |
| Communication | RS-485 / Ethernet / Modbus |
| Report Output | Auto PDF / Excel generation |
| Safety Protection | Over-current / over-temp / reverse / short-circuit / mis-operation prevention |
Technical Specifications
The technical specifications of the DFUN Battery Monitoring System outline the core performance metrics and design details that enable its reliable and versatile operation. These parameters provide a clear framework for understanding how the system meets diverse industry needs, from precision monitoring to robust compatibility.
Monitoring Parameters & Ranges
Voltage: 0 - 1500V (single cell), 0 - 10000V (battery string); measurement accuracy of ±0.1% FS, with a resolution of 1mV for precise cell-level tracking. Current: -500A to +500A (charge/discharge); accuracy ±0.2% FS, supported by a high-precision shunt resistor to capture even micro-current fluctuations. Temperature: -40°C to +85°C (ambient and cell-level); equipped with 16 built-in NTC sensors (expandable to 32) for multi-point monitoring, ensuring accuracy of ±0.5°C. Impedance: 0.01mΩ to 100mΩ; measured via AC excitation method at 1kHz frequency, with a resolution of 0.001mΩ to detect early cell degradation.
Cell Balancing
Type: Active balancing (energy transfer via inductive/capacitive coupling). Balancing current: Up to 5A, adjustable in 0.1A increments to match battery capacity. Balancing voltage difference threshold: 20mV - 200mV (user-configurable via software), with auto-balancing activation when discrepancies exceed the set value. Balancing efficiency: ≥90% to minimize energy loss during cell equalization.
Communication & Data Management
Protocols: Modbus RTU (RS485, baud rate 9600 - 115200bps), Modbus TCP (Ethernet, 10/100Mbps), SNMP v3 (for network management), MQTT (for IoT integration), and IEC 61850 (for smart grid compatibility). Interfaces: 2× RS485 ports (isolated, surge-protected), 1× Ethernet port (RJ45), 1× USB-C (for local configuration), and optional 4G/WiFi module (LTE Cat-M1, 802.11 b/g/n). Data update frequency: Configurable (1s - 60s), with real-time mode (1s interval) for critical applications like EVs. Storage capacity: 8GB internal flash memory, storing up to 1 year of historical data (at 5-minute intervals); supports data export via CSV/JSON.
Applicable Systems & Industries
Typical Applications:
Data centers, substations, IDC rooms, telecom base stations, industrial plants, and railway power systems.
UPS / Data-center systems (380 V / 480 V)
Telecom power systems (48 V)
Utility and substation DC systems (110 V / 220 V)
Why Choose DFUN?
Over 3,000 successful installations worldwide
Compatible with major UPS and battery brands
Supports open protocols: IEC / Modbus / SNMP
Provides remote maintenance and AI analysis services
OEM / system-integration customization available
Our Certificate
Our commitment to quality, safety, and compliance is reflected in the rigorous certifications the DFUN Battery Monitoring System has earned. These certifications validate that our product meets or exceeds global industry standards, ensuring reliability and peace of mind for users across diverse applications.
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Keep In Touch With Us
Stay connected with us to get the latest updates on the DFUN Battery Monitoring System, technical insights, and tailored solutions for your needs. We’re always here to listen and assist.
Mob：+86-15919182362
E-mail：info@dfuntech.com
